Vehicle seat

ABSTRACT

A vehicle seat includes a lower seat portion and a back portion. The lower seat portion and the back portion are formed from at least one panel by a method selected from the group consisting of quick plastic forming, superplastic forming and sheet hydroforming. The lower seat portion and the back portion are cooperatively configured to form a seat frame. Preferably, the lower seat portion includes a lower seat bottom panel portion and a matable lower seat top panel portion and the back portion includes a back bottom panel portion and a matable back top panel portion. The lower seat bottom panel portion, lower seat top panel portion, back bottom panel portion, and back top panel portion are preferably formed from a unitary, one-piece panel. A method of manufacturing a vehicle seat is provided.

TECHNICAL FIELD

This invention relates to a vehicle seat having a lower seat portion anda back portion formed by quick-plastic forming, superplastic forming orsheet hydroforming.

BACKGROUND OF THE INVENTION

Vehicle seat designs typically include a seatback frame and a lower seatframe. Typically, the seatback frame and the lower seat frame are formedfrom a multitude of components, such as metal tubing interconnected withsprings, to provide necessary rigidity and contoured support structureto the frame. Each of the tubular components and spring components mustbe separately formed. Additionally, the components must be assembled andjoined to provide the completed frame. The large number of framecomponents adds complexity, weight and cost to the finished seat.

SUMMARY OF THE INVENTION

A vehicle seat includes a lower seat portion and a back portion. Thelower seat portion and the back portion are formed from at least onepanel by a method selected from the group consisting of quick plasticforming, superplastic forming and sheet hydroforming. The lower seatportion and the back portion are cooperatively configured to form a seatframe.

Preferably, quick plastic forming is used to form the seatback portionand the lower seat portion. By utilizing quick plastic forming, complex,contoured shaping desirable for required component strength and rigidityas well as comfort considerations may be achieved with a unitary,one-piece panel, avoiding the use of a multitude of components to formthe seatback portion and the lower seat portion.

In one embodiment of the invention, the lower seat portion and the backportion are formed from a unitary, one-piece panel. In anotherembodiment, the lower seat portion is formed from a first unitary,one-piece panel and the back portion is formed from a second unitary,one-piece panel. The lower seat portion may have a lower seat bottompanel portion and a matable lower seat top panel portion. The backportion may have a back bottom panel portion and a matable back toppanel portion. The lower seat bottom panel portion and the lower seattop panel portion may be formed from a first unitary, one-piece paneland the back bottom panel portion and the back top panel portion may beformed from a second unitary, one-piece panel.

In another embodiment of the invention, the lower seat bottom panelportion and the back bottom panel portion are formed from a firstunitary, one-piece panel and the lower seat top panel portion and theback top panel portion are formed from a second unitary, one-piecepanel.

In yet another embodiment, the lower seat bottom panel portion and thelower seat top panel portion are formed from a first unitary, one-piecepanel and the back bottom panel portion and the back top panel portionare formed from a second unitary, one-piece panel.

In still another embodiment, the lower seat bottom panel portion, thelower seat top panel portion, the back bottom panel portion and the backtop panel portion are formed from a unitary, one-piece panel. Theone-piece panel is characterized by a first bend. The lower seat toppanel portion is on the first side of the first bend and the back toppanel portion is on the second side of the first bend. The one-piecepanel is further characterized by a second bend. The lower seat bottompanel portion is on a first side of the second bend and the lower seattop panel portion is on the second side of the second bend. Theone-piece panel is further characterized by a third bend. The back toppanel portion is on the first side of the third bend and the back bottompanel portion is on the side of the third bend.

The seat frame may be mountable with respect to a vehicle such that theseat frame is rigidly attached with respect to the vehicle.Alternatively, the seat frame may be matable with a seat track member.The seat track member may be mountable with respect to a vehicle and theseat frame may be movable along the seat track member relative to thevehicle. The lower seat portion and the back portion may be operablyconnectable to a pivot linkage such that the back portion is pivotablerelative to the lower seat portion. In one aspect of the invention, thelower seat portion, the back portion, or both, may be adapted to receivea seat cushion.

A method of manufacturing a vehicle seat is provided. The methodincludes forming a unitary one-piece panel by a method selected from thegroup consisting of quick plastic forming, superplastic forming andsheet hydroforming, wherein the panel has a first portion formed as alower seat portion and a second portion formed as a back portion. Thelower seat portion has a lower seat bottom panel portion and a lowerseat top panel portion. The back portion has a back bottom panel portionand a back top panel portion. The method may further include bending thepanel between the first portion and the second portion. The methodfurther includes bending the panel between the lower seat bottom panelportion and the lower seat top panel portion. The method may furtherinclude bending the panel between the back bottom panel portion and theback top panel portion. The method may further include joining the firstportion and the second portion to one another to form a seat frame.

The above features and advantages, and other features and advantages ofthe present invention are readily apparent from the following detaileddescription of the best modes for carrying out the invention when takenin connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective schematic view of a unitary, one-piece panelhaving a lower seat portion and a back portion in a progressive firstconfiguration;

FIG. 2 is a perspective schematic view of the panel in FIG. 1 in aprogressive intermediate configuration in which the panel is partiallybent;

FIG. 3 is a perspective schematic view of a first embodiment of avehicle seat formed from the panel of FIGS. 1 and 2 in a progressivefinal configuration;

FIG. 4 is a perspective schematic view of the seat of FIG. 3 mated witha seat track member on a vehicle and having cushions attached thereto;

FIG. 5A is a perspective schematic view of a unitary, one-piece backportion for use in a second embodiment of a vehicle seat;

FIG. 5B is a perspective schematic view of a unitary, one-piece lowerseat portion for use in the second embodiment;

FIG. 6A is a schematic plan view of a first unitary, one-piece panelhaving a back top panel portion and a lower seat top panel portion foruse in a third embodiment of a vehicle seat;

FIG. 6B is a schematic plan view of a second unitary, one-piece panelhaving a back portion panel portion and a lower seat bottom panelportion for use in the third embodiment;

FIG. 7A is a schematic plan view of a first unitary, one-piece panelhaving a lower seat bottom panel portion and a matable lower seat toppanel portion for use in a fourth embodiment of a vehicle seat;

FIG. 7B is a schematic plan view of a second unitary, one-piece panelhaving a back bottom panel portion and a matable top back panel portionfor use in the fourth embodiment;

FIG. 8A is a perspective schematic view of a back top panel portion foruse in a fifth embodiment of a vehicle seat;

FIG. 8B is a perspective schematic view of a back bottom panel portionfor use in the fifth embodiment;

FIG. 8C is a perspective schematic view of a lower seat top panelportion for use in the fifth embodiment;

FIG. 8D is a perspective schematic view of a lower seat bottom panelportion for use in the fifth embodiment;

FIG. 8E is a fragmentary perspective schematic view of the mated panelportion of FIGS. 8A-8D operatively connected to a pivot linkage; and

FIG. 9 is a flow chart diagram illustrating a method of manufacturing avehicle seat.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, wherein like reference numbers refer to likecomponents, FIG. 1 shows a unitary, one-piece seat frame panel 10. Seatframe panel 10 includes a lower seat portion 14 and a back portion 18.The lower seat portion 14 includes a lower seat top panel portion 22 anda lower seat bottom panel portion 26. The back portion 18 includes aback top panel portion 30 and a back bottom panel portion 34.

A first bend line 36, a second bend line 38 and a third bend line 40 areshown on the seat frame panel 10. The first bend line 36 (shown inphantom) is disposed between the back top panel portion 30 and the lowerseat top panel portion 22 such that the back top panel portion 30 is ona first side of the first bend line 42 and the lower seat top panelportion 22 is on a second side of the first bend line 44. The secondbend line 38 is disposed between the lower seat bottom panel portion 26and the lower seat top panel portion 22 such that the lower seat bottompanel portion 26 is on a first side of the second bend line 46 and thelower seat top panel portion 22 is on a second side of the second bendline 48. The third bend line 40 (shown in phantom) is disposed betweenthe back bottom panel portion 34 and the lower seat bottom panel portion26 such that the back bottom panel portion 34 is on a first side of thethird bend line 50 and the lower seat bottom panel portion 26 is on asecond side of a third bend line 52.

A multitude of attachment receiving openings 54 are cut into the seatframe panel 10. Mounting openings 56 are disposed in the lower seat topand bottom panel portions 22, 26, respectively. Vent openings 58 arealso cut in the seat frame panel 10. Preferably, the attachmentreceiving openings 54, the mounting openings 56 and the vent openings 58are cut into the seat frame panel 10 after forming of the panel 10. Aseat recession 62 is formed in the lower seat top panel portion 22 toenhance user comfort.

The one-piece panel 10 is formed with optional integral headrestportions 64. Additionally, the lower seat bottom panel portion 26 andthe back bottom panel portion 34 are formed with integral corrugations66 for strengthening such panels. The seat frame panel 10 is also formedwith a multitude of optional, integral flanges 68. The integral flanges68 include a first, second, third, fourth, fifth and sixth flange 70,72, 74, 76, 78, and 80, respectively. The first and second flanges 70,72 are disposed on the back bottom panel portion 34. The third flange 74is disposed on the lower seat bottom panel portion 26. The fourth flange76 is disposed on the lower seat top panel portion 22. The fifth andsixth flanges 78, 80, respectively, are disposed on the back top panelportion 30.

Quick plastic forming, superplastic forming or sheet hydroforming areemployed to form the contours of the lower seat portion 14 and the backportion 18 (such as the seat recess 62 and the corrugations 66) from anoriginally flat panel (not shown) to obtain a more complex shape than isgenerally achievable with stamping. As used herein, a “panel” means asheet of metal or plastic material, and may be referred to as such.Holes, apertures and openings are cut, punched, etc., after the contoursare formed.

Superplastic forming (SPF) is described in U.S. Pat. No. 5,974,847,issued Nov. 2, 1999 to Saunders, et al, which is hereby incorporated byreference in its entirety. When certain alloy compositions of steel oraluminum are suitably processed (such as with a very fine grainmicrostructure), they exhibit superplastic behavior at certain elevatedtemperatures. When deformed at these temperatures, the ductility (orelongation before yield or failure) of these materials exceeds severalhundred percent. Such high levels of ductility can enable fabrication ofvery complex structures in a single sheet of material. A panel 10 of thedesign discussed above can be fabricated in one piece using suchtechniques.

In addition to various steels and aluminum alloys, other structuralmaterials such as zinc, brass, magnesium, titanium and their alloys havealso been reported to exhibit superplastic behavior. Furthermore,certain polymers and reinforced polymer composites have the requiredductility to make this panel 10. These materials and other metal matrixcomposites could also be used to make the panel 10 of this invention, ifdesired.

In an example of superplastic forming, a blank, i.e., a sheet, istightly clamped at its edges between complementary surfaces of opposingdie members. At least one of the die members has a cavity with a formingsurface opposite one face of the sheet. The other die opposite the otherface of the sheet forms a pressure chamber with the sheet as one wall tocontain the working gas for the forming step. The dies and the sheet areheated to a suitable SPF condition for the alloy. For SPF aluminumalloys, this temperature is typically in the range of 400° C. to 550° C.Electric resistance heating elements are located in press platens orsometimes embedded in ceramic or metal pressure plates located betweenthe die members and the platens. A suitable pressurized gas such asargon is gradually introduced into the die chamber on one side of thesheet, and the hot, relatively ductile sheet is stretched at a suitablerate until it is permanently reshaped against the forming surface of theopposite die. The rate of pressurization is controlled so the strainrates induced in the sheet being deformed are consistent with therequired elongation for part forming. Suitable strain rates are usually0.0001 to 0.01 s⁻¹. During the deformation of the sheet, gas is ventedfrom the forming die chamber.

The '847 patent provides a method of stretch forming a ductile metalsheet into a complex shape involving significant deformation withoutexcessive thinning of the sheet material and without tearing it. Themethod is particularly applicable to the stretch forming of superplasticalloys heated to a superplastic forming temperature. In the method,additional material from the initially flat sheet blank is pulled ordrawn into the forming cavity for stretch forming. The additionalmaterial significantly reduces thinning and tearing in the formed part.

The method contributes to thickness uniformity in an SPF stretch-formedcomponent by utilizing controlled draw-in of sheet metal to the formingchamber prior to application of gas pressure. In an illustrativepractice, a preform, similar to a stationary male punch, is placed onthe forming press platen opposite the die cavity. An aluminum blank, forexample, is placed over the insert and heated to a suitable SPFtemperature for the alloy. The die is then moved toward its closedposition against the platen. In its closing motion, the die engages theedges of the aluminum sheet. The heated metal is pulled over and aroundthe insert, and draw-in of blank material thus occurs. This results in agreater amount of metal in the die cavity prior to SPF blow forming. Thequantity of additional metal can be managed by design of the size, shapeand location of the preform on the platen or complementary die member.But the additional metal in the die cavity reduces the amount of strainrequired and, hence, the amount of thinning to form a desired geometrycompared to conventional SPF.

Thus, by the judicious use of a suitable space-occupying metal preformon a die or platen member opposite the forming die, additional metal iseasily drawn into the cavity during die closure without significantlyincreasing the complexity of the tooling. Care is taken in the design ofthe preform to avoid excessive wrinkling of the drawn-in metal and tomaintain a tight gas seal at the periphery of the sheet upon full dieclosure. The uniformity in thickness of the stretch-formed part isimproved. Mass of the formed part can be reduced because the designerdoes not need to resort to thicker blanks to assure part quality. And,except for the simple preform, there is no increase in the complexity ofthe SPF tooling.

Quick plastic forming (QPF) is described in U.S. Pat. No. 6,253,588,issued Jul. 3, 2001 to Rashid, et al, which is hereby incorporated byreference in its entirety. For quick plastic forming, a preferred alloyis Aluminum Alloy 5083 having a typical composition, by weight, of about4% to 5% magnesium, 0.3 to 1% manganese, a maximum of 0.25% chromium,about 0.1% copper, up to about 0.3% iron, up to about 0.2% silicon, andthe balance substantially all aluminum. Generally, the alloy is firsthot and then cold rolled to a thickness from about one to about fourmillimeters.

In the AA5083 alloys, the microstructure is characterized by a principalphase of a solid solution of magnesium in aluminum withwell-distributed, finely dispersed particles of intermetallic compoundscontaining the minor alloying constituents, such as Al₆Mn.

Using QPF, large AA5083-type aluminum-magnesium alloy sheet stock may beformed into a complex three-dimensional shape with high elongationregions, like an SPF-formed part, at much higher production rates thanthose achieved by SPF practices. The magnesium-containing, aluminumsheet is heated to a forming temperature in the range of about 400° C.to 510° C. (750° F. to 950° F.). The forming may often be conducted at atemperature of 460° C. or lower. The heated sheet is stretched against aforming tool and into conformance with the forming surface of the toolby air or gas pressure against the back surface of the sheet. The fluidpressure is preferably increased continuously or stepwise from 0 psigage at initial pressurization to a final pressure of about 250 to 500psi (gage pressure, i.e., above ambient pressure) or higher. During thefirst several seconds up to about, e.g., one minute of increasingpressure application, the sheet accommodates itself on the tool surface.After this initial period of pressurization to initiate stretching ofthe sheet, the pressure can then be increased at an even faster rate.Depending upon the size and complexity of the panel to be formed, suchforming can normally be completed in a period of about two to twelveminutes, considerably faster than realized in superplastic forming.Thus, by working a suitably fine grained, aluminum alloy sheet atsignificantly lower temperatures and continuously increased, higher gaspressures than typical SPF practices, significantly faster and morepractical forming (at least for the automobile industry) times areachieved.

Referring to FIG. 2, the one-piece seat frame panel 10 is shown in anintermediate configuration with the back top panel portion 30 bent withrespect to the lower seat top panel portion 22 at the first bend line 36such that the back top panel portion 30 is rotated clockwise withrespect to the seat top panel portion 22. The back bottom panel portion34 is bent with respect to the lower seat bottom panel portion 26 at thethird bend line 40 such that the back bottom panel portion 34 is rotatedclockwise with respect to the lower seat bottom panel portion 26.

Referring to FIG. 3, the one-piece seat frame panel 10 of FIGS. 1 and 2is shown further bent between the lower seat top panel portion 22 andthe lower seat bottom panel portion 26 at the second bend line 38 suchthat the lower seat top panel portion 22 is mated with the lower seatbottom panel portion 26 and the back top panel portion 30 is mated withthe back bottom panel portion 34 to form a seat frame 82. When formed,the first flange 70 is mated with the sixth flange 80, the second flange72 is mated with the fifth flange 78 and the third flange 74 is matedwith the fourth flange 76. The mated flanges may be welded, bonded,hemmed or otherwise connected to one another to secure the lower seattop panel portion 22 to the lower seat bottom panel portion 26 and theback top panel portion 30 to the back bottom panel portion 34.Alternatively, if the one-piece seat frame panel 10 does not include theoptional flanges 70,72,74,76,78,80, welding, bonding, hemming, fasteningor other attachment means known to those skilled in the art may be usedto fasten the lower seat top panel portion 22 to the lower seat bottompanel portion 26 and the back top panel portion 30 to the back bottompanel portion 34.

Referring to FIG. 4, the one-piece panel 10 formed as the seat frame 82has cushion portions 86 attached at the attachment receiving openings54. The cushion portions 86 may be so attached with bolts, fasteners or,alternatively, snap-in components (not shown) attached to the cushionportions 86 and matable with the attachment receiving openings 56. Thecushion portions 86 may be separate portions as shown or may togetherform a one-piece cushion. Seat track members 90 operatively connected toa vehicle 92 are shown having seat mounting portions 94 matable withmounting openings 56 in the seat frame 82. Those skilled in the art willrecognize a variety of seat track members 90, seat mounting portions 94and mechanisms for attaching such to a seat frame. Alternatively, theseat frame 82 may be rigidly attached to the vehicle 92 either directlyor with a non-movable mount (not shown) disposed between the seat frame82 and the vehicle 92. Those skilled in the art will recognize a varietyof mechanisms for achieving rigid attachment between a seat frame 82 anda vehicle 92.

Referring to FIGS. 5A-5B, a lower seat portion 14A may be formed from aunitary, one-piece lower seat portion panel 96. A back portion 18A maybe formed from a unitary, one-piece back portion panel 98. The seatportion panel 96 is formed with an integral seat attachment portion 100.Likewise, the back portion panel 98 is formed with an integral backattachment portion 102 that is matable with the seat attachment portion100. Seat attachment portion 100 may be mated with the back attachmentportion 102 by a variety of means including fastening, bonding, hemmingand welding. When the seat attachment portion 100 and the backattachment portion 102 are mated (not shown), the seat portion panel 96and back portion panel 98 form an alternative seat frame 82A.

Referring to FIGS. 6A-6B, a lower seat top panel portion 22B and a backtop panel portion 30B are integrally formed from a unitary, one-piecetop panel portion 104 (i.e., a first, unitary, one-piece panel). Anintegral lower seat bottom panel portion 26B and a back bottom panelportion 34B are integrally formed from a unitary, one-piece bottom panelportion 106 (i.e., a second, unitary, one-piece panel). Referring toFIG. 6A, a first bend line 36B (shown in phantom) is disposed betweenthe lower seat top panel portion 22B and the back top panel portion 30Bsuch that the lower seat top panel portion 22B is on a first side 42B ofthe first bend line 36B and the back top panel portion 30B is on asecond side 44B of the first bend line 36B.

The one-piece top panel portion 104 and the one-piece bottom panelportion 106 include integral headrest attachment openings 108. Theheadrest attachment openings 108 may be formed in the top panel portion104 and bottom panel portion 106 or, preferably, cut therein afterforming. The headrest attachment openings 108 are configured to receivea headrest 110 shown in phantom.

Referring to FIG. 6B, a second bend line 38B is disposed such that thelower seat bottom panel portion 26B is disposed on a first side of thesecond bend line 46B and the back bottom panel portion 34B is disposedon a second side of the second bend line 48B. The top panel portion 104and the bottom panel portion 106 may be joined by connecting optionalflanges (not shown) similar to those shown on the one-piece panel 10 ofFIG. 1. Alternatively, the top panel portion 104 may be joined to thebottom panel portion 106 by laser welding at a periphery 111 of the toppanel portion and a periphery 112 of the bottom panel portion to form aseat frame 82B. Other attachment options known to those skilled in theart, such as adhesive bonding or fastening may also be used.

Referring to FIGS. 7A-7B, a unitary, one-piece seat portion panel 96C(i.e., a first, unitary, one-piece panel) and a unitary, one-piece backportion panel 98C (i.e., a second, unitary, one-piece panel) areillustrated. The seat portion panel 96C includes a lower seat topportion panel 22C and a lower seat bottom panel portion 26C separated bya first bend line 36C (shown in phantom) such that the top panel portion22C is on a first side of the first bend line 42C and the bottom panelportion 26C is on a second side of the first bend line 44C. The seatportion panel 96C may be bent at the first bend line 36C by rotatingbottom panel portion 26C in a clockwise downward direction toward thetop panel portion 22C to form a lower seat portion (not shown).Referring to FIG. 7B, the back portion panel 98C includes a back toppanel portion 30C and a back bottom panel portion 34C separated by asecond bend line 38C (shown in phantom). The second bend line 38C isdisposed between the back top panel portion 30C such that the back toppanel portion 30C is on a first side of the second bend line 46C and theback bottom panel portion 34C is on a second side of the second bendline 48C. The back portion panel 98C may be bent at the second bend line38C by rotating the back bottom panel portion 34C in a clockwisedirection downward toward the back top panel portion 30C to form a backportion (not shown). The seat portion panel 96C may be mated or joinedwith the back portion panel 98C by any of the alternative joiningmethods discussed herein.

In FIGS. 8A-8E, another embodiment of a seat frame is depicted.Referring to FIG. 8A, a unitary, one-piece back top panel portion 30D isillustrated. Referring to FIG. 8B, a unitary, one-piece back bottompanel portion 34D is illustrated. The back top panel portion 30D and theback bottom panel portion 34D may be mated or joined with one another byany of the methods discussed herein. The back top panel portion 30Dincludes an integral back top panel portion flange 114. Similarly, theback bottom panel portion 34D includes an integral back bottom portionflange 116. Referring to FIG. 8C, a unitary, one-piece lower seat toppanel portion 22D is depicted. The lower seat top panel portion 22D isformed with a deep recession 118 as well as an integral top panelportion flange 120. The recession 118 and the top panel portion flange120 are achievable through using the quick plastic forming, superplasticforming or sheet hydroforming processes.

Referring to FIG. 8D, a unitary, one-piece lower seat bottom panelportion 26D is depicted. The lower seat bottom panel portion 26Dincludes an integral lower seat bottom panel portion flange 124. Thelower seat top panel portion 22D and the lower seat bottom panel portion26D may be mated or joined by any of the methods discussed herein. Whenmated, the lower seat top panel portion flange 120 is also mated withthe lower seat bottom panel portion flange 124.

Referring to FIG. 8E, the mated lower seat top panel portion 22D and thelower seat bottom panel portion 26D form a lower seat portion 14D,including mated top panel portion flange 120 and lower seat bottom panelportion flange 124, forming a tube-like rod-receiving opening 128. Themated back top panel portion 30D and back bottom panel portion 34D forma back portion 18D including mated back top panel portion flange 114 andback bottom panel portion flange 116 which form a rod-receiving ringopening 130. A rod 134 (shown in phantom) is disposed through the rodreceiving ring opening 130 and the rod-receiving opening 128. The rod134 is operatively connected to a pivot linkage 138. Operation of thepivot linkage 138 allows the back portion 18D to pivot with respect tothe lower seat portion 14D. Those skilled in the art will realize avariety of pivot linkage mechanisms operable to achieve such pivoting.

Referring to FIG. 9, a method of assembling a seat 200 is shown in aflow chart. The method 200 includes forming a unitary, one-piece panel204 by a method selected from the group consisting of quick plasticforming, superplastic forming and sheet hydroforming, the panel having afirst portion having a lower seat bottom panel portion and a lower seattop panel portion and a second portion having a back bottom panelportion and a back top panel portion.

The method 200 may further include bending the panel between the firstportion and the second portion 208. The method 200 may further includebending the panel between the lower seat bottom panel portion and thelower seat top panel portion 212. The method 200 may further includebending the panel between the back bottom panel portion and the back toppanel portion 216. Bending 208, 212, 216 may be by press bending orother methods of bending known to those skilled in the art.

The method 200 may include joining the first portion and the secondportion 216 to one another to form a seat frame. Joining 216 may be bywelding, hemming, fastening, bonding or other methods known to thoseskilled in the art. The method 200 may further include providing 220 theseat frame formed according to step 204. The method 200 need not beperformed in the order shown in FIG. 9.

While the best modes for carrying out the invention have been describedin detail, those familiar with the art to which this invention relateswill recognize various alternative designs and embodiments forpracticing the invention within the scope of the appended claims.

1. A vehicle seat comprising: a lower seat portion; a back portion;wherein the lower seat portion and the back portion are formed from atleast one panel by a method selected from the group consisting of quickplastic forming, superplastic forming and sheet hydro-forming; andwherein the lower seat portion and the back portion are cooperativelyconfigured to form a seat frame.
 2. The vehicle seat of claim 1, whereinsaid at least one panel is a unitary, one-piece panel.
 3. The vehicleseat of claim 1, wherein said at least one panel includes a first,unitary, one-piece panel and a second, unitary, one-piece panel, whereinthe lower seat portion is formed from the first, unitary, one-piecepanel, and wherein the back portion is formed from the second, unitary,one-piece panel.
 4. The vehicle seat of claim 1, wherein the lower seatportion has a lower seat bottom panel portion and a matable lower seattop panel portion, and wherein the back portion has a back bottom panelportion and a matable back top panel portion.
 5. The vehicle seat ofclaim 4, wherein said at least one panel includes a first, unitary,one-piece panel and a second, unitary, one-piece panel, wherein thelower seat bottom panel portion and the lower seat top panel portion areformed from the first, unitary, one-piece panel, and wherein the backbottom panel portion and the back top panel portion are formed from thesecond, unitary, one-piece panel.
 6. The vehicle seat of claim 5,wherein the first, unitary, one-piece panel is characterized by firstbend, wherein the lower seat bottom panel portion is at a first side ofthe first bend and the lower seat top panel portion is at a second sideof the first bend, wherein the second, unitary, one-piece panel ischaracterized by a second bend, and wherein the back bottom panelportion is at a first side of the second bend and the back top panelportion is at a second side of the second bend.
 7. The vehicle seat ofclaim 4, wherein said at least one panel includes a first, unitary,one-piece panel and a second, unitary, one-piece panel, wherein thelower seat bottom panel portion and the back bottom panel portion areformed from the first, unitary, one-piece panel, and wherein the lowerseat top panel portion and the back top panel portion are formed fromthe second, unitary, one-piece panel.
 8. The vehicle seat of claim 7,wherein the first, unitary, one-piece panel is characterized by a firstbend, wherein the lower seat bottom panel portion is at a first side ofthe first bend and the back bottom panel portion is at a second side ofthe first bend, wherein the second, unitary, one-piece panel ischaracterized by a second bend, and wherein the lower seat top panelportion is at a first side of the second bend and the back top panelportion is at a second side of the second bend.
 9. The vehicle seat ofclaim 4, wherein said at least one panel is a unitary, one-piece panel;wherein the unitary, one-piece panel is characterized by a first bend,wherein the lower seat top panel portion is on a first side of the firstbend and the back top panel portion is on a second side of the firstbend; wherein the unitary, one-piece panel is further characterized by asecond bend, wherein the lower seat bottom panel portion is on a firstside of the second bend and the lower seat top panel portion is on asecond side of the second bend; wherein the unitary, one-piece panel isfurther characterized by a third bend; and wherein the back top panelportion is on a first side of the third bend and the back bottom panelportion is on a second side of the third bend.
 10. The vehicle seat ofclaim 1, wherein the seat frame is mountable with respect to a vehiclesuch that the seat frame is rigidly attached with respect to thevehicle.
 11. The vehicle seat of claim 1, wherein the seat frame ismatable with a seat track member, wherein the seat track member ismatable with respect to a vehicle, and wherein the seat frame is movablealong the seat track member relative to the vehicle.
 12. The vehicleseat of claim 1, wherein the lower seat portion and the back portion areoperably connectable to a pivot linkage such that the back portion ispivotable relative to the lower seat portion.
 13. The vehicle seat ofclaim 1, wherein one of the lower seat portion and the back portion isadapted to receive a seat cushion.
 14. The vehicle seat of claim 1,wherein the back portion is adapted to receive a headrest.
 15. Thevehicle seat of claim 1, wherein the back portion is formed with aheadrest portion.
 16. The vehicle seat of claim 1, wherein one of thelower seat portion and the back portion is formed with an integralflange, and wherein said integral flange is connectable with respect tothe other of the lower seat portion and the back portion to at leastpartially join said one with respect to said other.
 17. A method ofmanufacturing a vehicle seat, the method comprising: forming a unitary,one-piece panel by a method selected from a group consisting of quickplastic forming, superplastic forming and sheet hydroforming, whereinthe unitary, one-piece panel has a first portion formed as a lower seatportion and a second portion formed as a back portion, wherein the lowerseat portion has a lower seat bottom panel portion and a lower seat toppanel portion, and wherein the back portion has a back bottom panelportion and a back top panel portion.
 18. The method of claim 17,further comprising: bending the unitary, one-piece panel between thefirst portion and the second portion; bending the unitary, one-piecepanel between the lower seat bottom panel portion and the lower seat toppanel portion; and bending the unitary, one-piece panel between the backbottom panel portion and the back top panel portion.
 19. The method ofclaim 17, further comprising joining the first portion and the secondportion to one another to form a seat frame.
 20. The method of claim 17,further comprising providing the formed panel as a seat frame.
 21. Avehicle seat comprising: a lower seat portion; a back portion; whereinthe lower seat portion has a lower seat bottom panel portion and amatable lower seat top panel portion, wherein the back portion has aback bottom panel portion and a matable back top panel portion; whereinthe lower seat bottom panel portion, the lower seat top panel portion,the back bottom panel portion and the back top panel portion are formedfrom a unitary, one-piece panel; wherein the lower seat portion and theback portion are formed by quick plastic forming; and wherein the lowerseat portion and the back portion are cooperatively configured to form aseat frame.